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Unread 02-25-2007, 02:53 PM   #1
tmwoodall
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Installing Aussie

I was going to go to a shop and have them do it. But now I am so close to going home now that I am thinking I might try this out on my own. How hard is it? A guy in my club said it took him several hours for the lack of tools and first time trying something like that. I have the tools and the space. How hard is it actually 4x4explor makes it look like a two hour job which I know it is not....

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Unread 02-25-2007, 02:56 PM   #2
SecondTJ
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since there is no adjustments needed with it (backlash, pinion preload, etc) it is a fairly straight forward install with the right tools
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Unread 02-25-2007, 04:05 PM   #3
tmwoodall
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Ok Thanks I think I will give it a shot and buy myself a muffler instead of having it installed.
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Unread 02-25-2007, 04:11 PM   #4
Lostj
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I put one in my d30 and it was very easy.
The only things that gave me trouble was:
trying to "pop" the carrier out of the axle
and
trying to get the carrier to stay put on the tiny vice that I was using when i was taking on/off the ring gear bolts.

this is what worked for me for getting the carrier out:

http://www.stu-offroad.com/axle/d30seals/seal-5.jpg
(http://www.stu-offroad.com/axle/d30seals/seal-1.htm)


and here are some write-ups:

http://www.offroadlockers.com/manual...d0f/4e25/.html

http://www.jeepforum.com/forum/f37/how-install-lunchbox-locker-ex-locker-aussie-locker-etc-your-d30-axle-115029/

http://mrpistol.tripod.com/id58.html

http://home.off-road.com/~nobucks/locker.html

I printed this one out:
http://www.4x4xplor.com/aussielocker.html
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lx015oɹd uǝpıun 'ɥɔuıʍ ql0009ɟɥ ؛ɹǝıɹɹɐɔ ǝɹıʇ pol 'sɹǝpuǝɟ ǝqnʇ pǝɹɐlɟ"5˙4ʇuʇ :˙ɔsıɯ ؛sɹǝpıls sʞɹoʍʞɔoɹɥs 'pıʞs ǝuıƃuǝ ɔıpǝɯdǝǝɾ 'pıʞs ɹoʇɐıpɐɹ s,ʎʇsnɹ 'ʞuɐʇsɐƃ puɐ xoq ƃuıɹǝǝʇs ʇɥƃıɹuǝƃ :spıʞs ؛pɐoɹɟɟo ɹoɟ sɹǝƃƃoq"53 'ʇǝǝɹʇs ɹoɟ s,ʇ/ɯdɯoɔoɹd"53 :sǝɹıʇ ؛lɯɯ"1 'lq"52˙1 'spq "2 :ʇɟıl ؛ɹǝʌoɔ uǝɯʞoɹ 'loods-ıuıɯ 'sǝʞɐɹq ɔsıp 'sʎollɐ ɥʇıʍ 44p ؛ɹǝʌoɔ ɹǝɥsnɹɔʞɔoɹ 'slɐǝs ǝlxɐ ɹǝʇno 'ɹǝʞɔol ǝıssnɐ 'sʎollɐ /ʍ 03p '6ı :ɾʇ,00
44p '03p '6ı :5ɾɔ,37
s,ʇ/ɐ ƃɟq"23 '44p '03p '8ʌ063 :5ɾɔ,47

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Unread 02-25-2007, 04:59 PM   #5
Chris_
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Quote:
Originally Posted by oreo
trying to get the carrier to stay put on the tiny vice that I was using when i was taking on/off the ring gear bolts.
that was the only thing that gave me a headache. my vice is bolted to a pretty big workbench, and it was still a pain. i ended up getting a socket wrench on each one, then hammering at it with a mallet. if i just tried to push it, my bench would start moving.

other than that, mine just took about 3 hours by myself.
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Unread 02-25-2007, 08:50 PM   #6
tmwoodall
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awesome guys thanks. I am going to get a muffler instead of having it installed
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Unread 02-25-2007, 09:28 PM   #7
SilverJ
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I removed the ring gear with an impact and never used a vice, even though I do have one! Anb, with the proper tools it was a two hour job. Though the previous weekend I Miller locked the rear, and that was a little more in depth. Good luck!! You will laugh at how easy it was once you are finished. Tell us all how it went!
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Unread 02-25-2007, 09:31 PM   #8
Tacoma750
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Sometimes the aussie requiers grinding to the housing to make it fit....Some do some dont.Mine did
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Unread 02-25-2007, 09:47 PM   #9
Lostj
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Quote:
Originally Posted by Tacoma750
Sometimes the aussie requiers grinding to the housing to make it fit....Some do some dont.Mine did
what axle?
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lx015oɹd uǝpıun 'ɥɔuıʍ ql0009ɟɥ ؛ɹǝıɹɹɐɔ ǝɹıʇ pol 'sɹǝpuǝɟ ǝqnʇ pǝɹɐlɟ"5˙4ʇuʇ :˙ɔsıɯ ؛sɹǝpıls sʞɹoʍʞɔoɹɥs 'pıʞs ǝuıƃuǝ ɔıpǝɯdǝǝɾ 'pıʞs ɹoʇɐıpɐɹ s,ʎʇsnɹ 'ʞuɐʇsɐƃ puɐ xoq ƃuıɹǝǝʇs ʇɥƃıɹuǝƃ :spıʞs ؛pɐoɹɟɟo ɹoɟ sɹǝƃƃoq"53 'ʇǝǝɹʇs ɹoɟ s,ʇ/ɯdɯoɔoɹd"53 :sǝɹıʇ ؛lɯɯ"1 'lq"52˙1 'spq "2 :ʇɟıl ؛ɹǝʌoɔ uǝɯʞoɹ 'loods-ıuıɯ 'sǝʞɐɹq ɔsıp 'sʎollɐ ɥʇıʍ 44p ؛ɹǝʌoɔ ɹǝɥsnɹɔʞɔoɹ 'slɐǝs ǝlxɐ ɹǝʇno 'ɹǝʞɔol ǝıssnɐ 'sʎollɐ /ʍ 03p '6ı :ɾʇ,00
44p '03p '6ı :5ɾɔ,37
s,ʇ/ɐ ƃɟq"23 '44p '03p '8ʌ063 :5ɾɔ,47

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Unread 02-25-2007, 10:02 PM   #10
JamboreeTJ
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You need a long punch to remove the cross shaft. NAPA should have one.

You need a large enough vise to properly torque the ring gear after putting the Aussie in.

It is a good mod to do yourself. You'll learn a lot.
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Unread 02-25-2007, 10:31 PM   #11
Tacoma750
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Dana30 is the axle that SOMETIMES needs the housing ground
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Unread 02-25-2007, 10:36 PM   #12
Lostj
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Quote:
Originally Posted by Tacoma750
Dana30 is the axle that SOMETIMES needs the housing ground
when I did mine I thought I was going to have to do that, but I changed the order that I was putting the gears in and they went in smoothly and I had no problems

all jeep are different
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lx015oɹd uǝpıun 'ɥɔuıʍ ql0009ɟɥ ؛ɹǝıɹɹɐɔ ǝɹıʇ pol 'sɹǝpuǝɟ ǝqnʇ pǝɹɐlɟ"5˙4ʇuʇ :˙ɔsıɯ ؛sɹǝpıls sʞɹoʍʞɔoɹɥs 'pıʞs ǝuıƃuǝ ɔıpǝɯdǝǝɾ 'pıʞs ɹoʇɐıpɐɹ s,ʎʇsnɹ 'ʞuɐʇsɐƃ puɐ xoq ƃuıɹǝǝʇs ʇɥƃıɹuǝƃ :spıʞs ؛pɐoɹɟɟo ɹoɟ sɹǝƃƃoq"53 'ʇǝǝɹʇs ɹoɟ s,ʇ/ɯdɯoɔoɹd"53 :sǝɹıʇ ؛lɯɯ"1 'lq"52˙1 'spq "2 :ʇɟıl ؛ɹǝʌoɔ uǝɯʞoɹ 'loods-ıuıɯ 'sǝʞɐɹq ɔsıp 'sʎollɐ ɥʇıʍ 44p ؛ɹǝʌoɔ ɹǝɥsnɹɔʞɔoɹ 'slɐǝs ǝlxɐ ɹǝʇno 'ɹǝʞɔol ǝıssnɐ 'sʎollɐ /ʍ 03p '6ı :ɾʇ,00
44p '03p '6ı :5ɾɔ,37
s,ʇ/ɐ ƃɟq"23 '44p '03p '8ʌ063 :5ɾɔ,47

The Swamp Things 4x4 Club Jeep Talk HomeGrown Offroad
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Unread 02-26-2007, 11:57 AM   #13
PeteC
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Quote:
Originally Posted by Tacoma750
Dana30 is the axle that SOMETIMES needs the housing ground
I can't even think of a spot where grinding might even have been remotely needed. But I guess that's just me.
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